Fuel Tank: Testing and Inspection

WARNING:
- Before attempting "Fuel Tank Leak Check" place a dry chemical (Class B) fire extinguisher near work area.
- Before removing the fuel tank for a suspected leak, make sure fuel pipes are not leaking onto the tank. Once removed, make sure fuel is not leaking around fuel sender assembly O-ring.
- This check requires a fuel sender assembly and O.ring to be installed in the fuel tank.

FUEL TANK LEAK CHECK
1. Relieve fuel system pressure. Refer to Fuel System / Service and Repair. [1][2]Fuel System Pressure Relief Procedure
2. Drain fuel tank.
3. Remove fuel tank.
4. Cap fuel feed pipe, fuel return pipe and Evaporative Emissions (EVAP) pipe on fuel sender assembly.
5. Plug fuel filler pipe opening.
6. Connect a piece of hose to the vent pipe.
7. Submerge tank in water or apply soap solution to outside of tank.
8. Apply 7 to 10 kPa (1 to 1.5 psi) air pressure to the piece of hose on the fuel tank vent pipe.
- Air bubbles appearing from fuel tank indicate a leak. Replace fuel tank if it is leaking.